Method for the production of moulds

Abstract

A method is disclosed for producing a mould that is suitable for moulding a tool that is suitable for providing support and shape to a preform made of composite material, in which the mould defines a forming die provided with a forming surface with double curving, the method providing the forming of a monolithic solid by an additive manufacturing technique in a construction direction, the monolithic solid comprising a sandwich structure of curved shape that extends between two end edges extending in length in the construction direction, the sandwich structure comprising an inner core that has a section with a corrugated profile.

1 . Production method, including the steps of:
 forming a monolithic solid (S) by an additive manufacturing technique in a construction direction ( 5 ), said monolithic solid (S) comprising at least one outer surface ( 1 ) and one inner surface ( 2 ); and   finishing said outer surface ( 1 ) so as to make it suitable and usable as a moulding die to mould an object (Z).   
     
     
         2 . Method according to  claim 1 , wherein said step of finishing said outer surface ( 1 ) comprises the steps of:
 operating a mechanical processing; and   depositing material on the outer surface (i).   
     
     
         3 . Method according to  claim 2 , wherein said step of finishing said outer surface ( 1 ) is carried out by a CNC mechanical processing of said outer surface ( 1 ) and, subsequently, by depositing a fibrous material on the finished part. 
     
     
         4 . Method according to  claim 2 , wherein said step of finishing said outer surface ( 1 ) is carried out by depositing a layer ( 7 ) of material, for example epoxy pasty material, and subsequently by CNC mechanical processing of said layer ( 7 ). 
     
     
         5 . Method according to  claim 1 , comprising the steps of:
 arranging said monolithic solid (S) in an operative position in which said outer surface ( 1 ) is facing upwards;   using said outer surface ( 1 ) facing upwards as a forming die to mould the object (Z).   
     
     
         6 . Method according to  claim 1 , wherein said outer surface ( 1 ) is at least partly convex and said inner surface ( 2 ) is at least partly concave. 
     
     
         7 . Method according to  claim 1 , wherein said outer surface ( 1 ) is at least partly concave and said inner surface ( 2 ) is at least partly convex. 
     
     
         8 . Method according to  claim 1 , wherein said monolithic solid (S) comprises a sandwich structure comprising at least one intermediate portion ( 4 ) acting as a connection core between said outer surface ( 1 ) and said inner surface ( 2 ). 
     
     
         9 . Method according to  claim 8 , wherein a section of said intermediate portion ( 4 ) made according to a plane orthogonal to said construction direction ( 5 ) has a corrugated profile. 
     
     
         10 . Method according to  claim 9 , wherein said corrugated profile includes a regular sinusoidal profile. 
     
     
         11 . Method according to  claim 8 , wherein said sandwich structure is provided with a curved shape which develops between two end edges ( 3 ) which are distant from each other and which are extended in length in said construction direction ( 5 ). 
     
     
         12 . Method according to  claim 11 , comprising the step of arranging said monolithic solid (S) in an operative position in which said outer surface ( 1 ) is facing upwards, in said operating position said two end edges ( 3 ) being fixed to a support structure ( 6 ). 
     
     
         13 . Method according to  claim 1 , wherein said monolithic solid (S) comprises two or more sections which are fixed to each other and in turn fixed to a supporting structure ( 6 ). 
     
     
         14 . Method according to  claim 13 , wherein said two or more sections are fixed together by gluing and are fixed to said support structure ( 6 ) by structural bonding. 
     
     
         15 . Method according to  claim 1 , wherein an inclination of said outer surface ( 1 ) with respect to said construction direction ( 5 ) is in the range ±45°. 
     
     
         16 . Method according to  claim 1 , wherein an inclination of said inner surface ( 2 ) with respect to said construction direction ( 5 ) is in the range f  450 . 
     
     
         17 . Mould, in particular made by a method according to  claim 1 , including a monolithic solid (S) produced by an additive manufacturing technique in a construction direction ( 5 ), said monolithic solid (S) comprising at least one outer surface ( 1 ) and an inner surface ( 2 ), said outer surface ( 1 ) being suitable and usable as a moulding die for moulding an object (Z). 
     
     
         18 . Mould according to  claim 17 , wherein:
 said monolithic solid (S) includes at least one sandwich structure comprising at least one intermediate portion ( 4 ) acting as a connection core between said outer surface ( 1 ) and said inner surface ( 2 );   said sandwich structure is developed with a curved shape comprised between two end edges ( 3 ) extended in length in said construction direction ( 5 ) and distant from each other,   a section of said intermediate portion ( 4 ) according to a plane orthogonal to said construction direction ( 5 ) has a corrugated profile.   
     
     
         19 . Mould according to  claim 18 , wherein:
 said monolithic solid (S) includes two or more sections fixed to each other and/or fixed to a supporting structure;   an inclination of said outer surface (I) with respect to said construction direction ( 5 ) is in the range ±45°.   
     
     
         20 . Mould according to  claim 19 , wherein a tilt of said inner surface ( 2 ) with respect to said construction direction ( 5 ) is in the range ±45°.